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At least 163 records · Page 9

Assessment of Cladding-Cladding Delamination Failures in U-Mo Fuel Plates

Monolithic fuel is a candidate fuel form for the conversion of high-performance research reactors. This plate-type fuel consists of a high-density, U-Mo alloy-based fuel in a monolithic form that is sandwiched between zirconium diffusion barriers and encapsulated in an aluminum cladding. To qualify this fuel system, the program must demonstrate that the fuel meets the safety standards, has a predictable behavior, and performs well in a reactor. Although many plates have shown satisfactory thermo-mechanical performance in reactor, a small number of experimental plates exhibited failures, rendering performance of these plates unacceptable. Post-irradiation examinations of failed plates have revealed that various failures modes are present, including pillowing, blistering, buckling, warping, delamination, fracture, rupture, oxide spallation, etc. Previous studies have implied that such various operational and loading conditions could generate a complex stress-strain state, facilitating distinct failure modes that could impact the structural integrity. To understand such various failure modes, a comprehensive set of studies focusing on failure modes is being performed. As a part of these studies, this work studies the cladding-cladding separation failures that were observed in some of previous irradiation tests. To understand the root cause of cladding separation failures, selected plates from previous irradiation experiments were simulated under comparable operational conditions. Stress-strain state of the plates at the interface were examined. The results were comparatively evaluated to understand possible effects of stress state of the bond-line on delamination failures. This paper presents these findings, discusses such failure modes, and examines the influence of various factors on previously observed cladding delamination failures.

42 ENGINEERING↗

Quantify Contaminant Partitioning in Advanced Chlorination Process

Chlorination of the zirconium in spent fuel cladding has been identified as a significant means of Zr recovery and purification, enabling a 25% (wt.) or greater reduction in waste requiring geologic disposition. Several chlorinating agents have been identified over the last few years, including gases and liquids. In particular, the interactions of sulfur-chloride solvents with zirconium may allow the separation of zirconium from uranium with the selective formation of ZrCl 4 . This report reviews what is known about reactions between chlorinating agents, uranium metal and oxide, Zircaloy and its alloying elements, and fission plus activation products. Plans for testing the feasibility of applying advanced chlorination methods developed for zirconium recycling to the front end of the recycling of spent nuclear fuel are also included.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Silicon carbide reinforced zirconium based cladding

A method for making an improved nuclear fuel cladding tube includes reinforcing a Zr alloy tube by first winding or braiding ceramic yarn directly around the tube to form a ceramic covering, then physically bonding the ceramic covering to the tube by applying a first coating selected from the group consisting of Nb, Nb alloy, Nb oxide, Cr, Cr oxide, Cr alloy, or combinations thereof, by one of a thermal deposition process or a physical deposition process to provide structural support member for the Zr tube, and optionally applying a second coating and optionally applying a third coating by one of a thermal deposition process or a physical deposition process. If the tube softens at 800° C.-1000° C., the structural support tube will reinforce the Zr alloy tube against ballooning and bursting, thereby preventing the release of fission products to the reactor coolant.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Structure of the pellet-cladding interaction layer of a high-burnup Zr-Nb-O nuclear fuel cladding

Here, structure of the pellet/cladding-interaction (PCI) layer of a high-burnup nuclear fuel with niobium-bearing cladding was investigated using modern transmission electron microscopy (TEM) techniques. Morphology of the PCI consisted of uniform zirconia layer on the cladding side and finger-like features towards to the ceramic fuel. The PCI layer showed a complex microstructure that constitutes three distinct zirconia layers formed by two zirconia phases. From cladding to fuel, monoclinic, tetragonal, and another tetragonal phase were determined via TEM diffraction patterns and precession electron diffraction (PED) using ASTAR microscopy platform (AMP). Characterizations showed that monoclinic and tetragonal phases close to the cladding were crack-free, but the tetragonal layer adjacent to the fuel contained cracks and pores. Presence of the monoclinic layer suggested that its formation involved the gaseous diffusion of oxygen below threshold dose of fission product damage before the fuel/cladding contact occurred. Furthermore, high-resolution TEM revealed compound phase of (U,Zr)O 2 at fringes of zirconia fingers on the fuel side.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

MPEX High Heat Flux Plasma Dump Design, Manufacture, and Articles Test

Here, the Material Plasma Exposure eXperiment (MPEX) device is a steady-state linear plasma device currently in the final design phase at the Oak Ridge National Laboratory. This device will reach ion fluences up to 10 31 m -2 and will be used to expose neutron-irradiated materials to divertor-relevant plasmas and to study the effects of plasma-material interactions. These studies will elucidate the complex effects of plasmas with divertor candidate materials capable of withstanding high heat flux and high fluences for next-generation fusion devices. Bidirectional plasma will be generated using a high-power (200 kW) helicon source. Plasma will be confined by superconducting magnets. The last plasma-facing component on the upstream side of the MPEX device is the dump, which has been designed to intercept plasma and energetic particles. The dump will have a total heat load of 9.2 kW. A copper alloy (Glidcop AL-15) was selected for use in the water-cooled flange design because of its high thermal conductivity, its retaining strength at elevated temperatures, and its ability to be used in the high-temperature braze joints used in this application. Titanium-zirconium-molybdenum (TZM) tiles are brazed to the Glidcop AL-15 flange using high-temperature braze alloy. External water-cooling channels are used on the dump flange to prevent water leakage inside the vacuum space. This article discusses the details of the high heat flux dump design, including the computational fluid dynamics (CFD) and structural analyses performed to validate the design to meet the operational requirements of the MPEX device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Tetragonal structure and uniaxial magnetic anisotropy in the arc-melted (Ce,Zr) 2 (Fe,M) 17 (M = Mo, W, Co) alloys

The tetragonal ThMn 12 -type structure is stabilized in (Ce 1-x Zr x ) 2 T 16 M (x = 0.2 – 0.3; T = Fe or Fe/Co, M = Mo or W) arc-melted alloys. Approximately 5 at% of Mo or W admixture is sufficient to transform the hexagonal Th 2 Ni 17 -type structure of (Ce 1-x Zr x ) 2 Fe 17 into the tetragonal ThMn 12 -type structure of nearly single-phase (Ce 1-x Zr x ) 2 Fe 16 M and/or (Ce 1-x Zr x ) 2 Fe 15 CoM bulk alloys. X-ray Rietveld refinements reveal that Zr and Mo (W) substitute different sites in the tetragonal crystal structure. Zirconium preferentially replaces Ce, whereas Mo (W) substitutes Fe. At room temperature, the tetragonal phases exhibit strong ferromagnetism and a uniaxial magneto-crystalline anisotropy with anisotropy fields of 15 – 17 kOe. These materials possess room-temperature saturation magnetizations of 95 – 105 emu/g and Curie temperature of 420 – 505 K. At some concentrations, concurrent Zr and Mo (W) site occupancy facilitates 1:12 structure formation in bulk alloys with minimal presence of non-magnetic element in the Fe sublattice, thus securing the highest known magnetic moment per Fe atom (∼ 1.37 µ B ) in this type of materials. The intrinsic magnetic characteristics, as well as the absence of critical rare earths (RE), make these compounds interesting for development as low-cost permanent magnets. In conclusion, small Co additions improve the Curie temperature, especially if combined with W.

36 MATERIALS SCIENCE↗

Unveiling the nucleation and growth of Zr oxide precipitates in internally oxidized Nb3Sn superconductors

We report on atomic-scale analyses of nucleation and growth of Zr oxide precipitates and the microstructural evolution of internally oxidized Nb3Sn wires for high-field superconducting magnet applications, utilizing atom probe tomography (APT), transmission electron microscopy (TEM), and first-principles calculations. APT analyses reveal that oxygen and zirconium are already segregated at grain boundaries (GBs) in the unreacted Nb-1Zr-4Ta (at%) alloy prior to forming Nb3Sn through reacting the Nb alloy with Sn and SnO2. After forming Nb3Sn, Zr oxide precipitates nucleate both at the Nb3Sn/Nb heterophase interfaces and in the Nb3Sn grains, driven by the small solubilities of Zr and O in Nb3Sn compared to their value in Nb. A high number density (Nv) of Zr oxide nanoprecipitates is observed in the Nb3Sn layers, ∼10 23 m −3 , with a mean diameter <10 nm for a heat treatment at 625 °C. Quantitative APT and TEM analyses of the Zr oxide precipitates in the reacted Nb3Sn layers elucidate details of the nucleation, growth, and coarsening processes of the Zr oxide precipitates in Nb3Sn. First-principles calculations and classical nucleation theory are employed to study the nucleation of Zr oxide precipitates in Nb3Sn and to estimate the maximum energy barrier and critical radius for nucleation. Our research unveils the kinetic pathways for nucleation and growth of Zr oxide precipitates and the microstructural evolution of Nb3Sn layers, which helps to understand and improve the superconducting properties of internally oxidized Nb3Sn wires for use in high-field superconducting magnets. •We investigated the nucleation and growth of Zr oxide nanoprecipitates in Nb3Sn superconductors for magnet applications.•APT and TEM analyses reveals the nucleation and growth process of Zr oxide precipitates in Nb3Sn layers.•Classical nucleation theory with DFT is employed to describe the nucleation process of Zr oxide precipitates in Nb3Sn.•We find that the interfacial reactions at Nb/Nb3Sn interface play a critical role in the nucleation of Zr oxide precipitates.•Current study provides a pathway to improve the properties of internally oxidized Nb3Sn superconducting wires.

43 PARTICLE ACCELERATORS↗

Chemistry effects on ODS steel consolidated via laser powder bed fusion from GARS powder

Oxide Dispersion Strengthened (ODS) steels are promising candidate alloys for structural and cladding applications in extreme environments. They contain a high density of nanoscale oxides for high temperature mechanical strength and radiation resistance. In this work, gas atomization reaction synthesis (GARS) was used to produce powders that were used for additive manufacturing (AM) Laser Powder Bed Fusion consolidation of ODS steels, in order to skip the traditional mechanical alloying of blended yttria and alloy powders. Powder containing iron, chromium, and tungsten with varying amounts of yttrium, titanium, oxygen and zirconium were used to produce ODS steel samples. AM consolidated specimens and powder samples were characterized with transmission electron microscopy. TEM imaging, diffraction patterns, and energy dispersive X-ray spectroscopy (EDS) was used to identify phases present before and after consolidation across chemistries. The effect of the controlled oxygen input (from GARS) and the oxide-forming additions (Y, Ti, Zr) on precipitate size distribution and composition is substantiated and discussed.

36 MATERIALS SCIENCE↗

Isotropic nanocrystalline Sm(Fe,Co) 11.3 Ti 0.7 magnets modified with B and Zr

Rare-earth-lean Sm(Fe,Co,Ti) 12 alloys with the ThMn 12 crystal structure and less than one Ti atom per formula unit have the potential of exceptionally powerful permanent magnets, but all prior attempts to develop high coercivity in bulk alloys, especially coercivity combined with crystallographic texture, have fallen short of the expectations. This study was aimed at improvement of the currently best Sm(Fe,Co,Ti) 12 magnets prepared through melt-spinning which are inherently isotropic. Modifications of the alloys with B and Zr, already demonstrated in earlier studies to be effective separately, have been implemented simultaneously. Here, a systematic study of Sm 1.1-x (Fe,Co) 11.3-y Ti 0.7 B y alloys melt-spun at a tangential speed of 50 m/s and annealed at 600–950 °C allowed for monitoring the continuous evolution of the two consecutive crystal structures, those of the TbCu 7 and ThMn 12 types. Zirconium was found to facilitate the formation of the 1:12 structure at the expense of the 1:7, whereas boron has the opposite effect, at certain concentrations completely suppressing the 1:12. When the two alloying elements are introduced simultaneously, they inhibit growth of the 1:12 crystallites at annealing temperatures higher than 800 °C, thus allowing for the development of a higher coercivity. Because of instrumental limitations, bulk magnets were prepared through a two-step process – compaction of the melt-spun ribbons at 650 °C and additional treatment at a higher temperature – and they were characterized by a reduced, 90–93%, density. Nevertheless, an isotropic Sm 0.9 Zr 0.2 (Fe,Co) 10.8 Ti 0.7 B 0.5 magnet exhibited fair values of the remanence (7.4 kG), maximum energy product (8.5 MGOe) and coercivity (5.4 kOe), as well as high Curie temperature of 525 °C and remarkably small temperature coefficient of the coercivity, -0.25%/°C.

36 MATERIALS SCIENCE↗

Material Plasma Exposure eXperiment (MPEX) High Heat Flux Bellows for Component Alignment in High Microwave Environment

The Material Plasma Exposure eXperiment (MPEX) device is a linear plasma device developed to perform plasma material interaction experiments under the conditions prototypic of a fusion reactor divertor. MPEX has multiple systems that must be precisely aligned to the plasma axis, including an electron cyclotron heating system that emits up to 400 kW of microwave power into the vacuum vessel. Five distinct systems require precise alignment on the MPEX device, thus requiring four bellows, all of which are adjacent to the plasma at a relatively high heat flux of approximately 47 kW/m2 and microwave power regions. The MPEX high heat flux bellows (HHFB) is designed to deliver 6 degrees of freedom positioning. The HHFB includes titanium–zirconium–molybdenum (TZM) inserts that are brazed into a Glidcop AL-15 body using a high-temperature braze alloy, thus blocking direct line of sight to an edge-welded bellows from the plasma and microwave screen to block microwaves from the bellows. Further, a custom ConFlat knife edge is machined into the Glidcop AL-15, so the vacuum flanges do not need a braze or weld joint on the vacuum interface. Fingerstock or copper mesh is used to restrict microwave power from entering the interstitial space between the water-cooled Glidcop AL-15 body and edge-welded bellows. Glidcop AL-15 was selected as the material of choice for the water-cooled body because it can maintain mechanical integrity at elevated temperatures, and it also allows for a high-temperature braze. TZM was selected for its machinability and compatibility with vacuum and plasma requirements. A test article is also being considered for a similarly shaped component, the MPEX limiter, that will demonstrate the integrity of the braze joint under high thermal load. Results from this testing will be extrapolated to deduce the lifetime and integrity of the HHFB design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Cast iron alloy for automotive engine applications with superior high temperature oxidation properties

A cast iron alloy is provided with a composition in weight percent (wt. %) of carbon between 2.6 to 3.4 wt. %, silicon between 2.4 to 3.2 wt. %, manganese between 0.3 to 0.6 wt. %, molybdenum between 0.4 to 1.2 wt. %, nickel between 0.6 to 1.75 wt. %, magnesium between 0.01 to 0.075 wt. %, aluminum between 1.8 to 3.5 wt. %, sulfur between 0.003 to 0.025 wt. %, zirconium between 0.001 to 0.02 wt. %, cerium between 0.001 to 0.03 wt. %, lanthanum between 0.0005 to 0.02 wt. %, and a balance of iron and unavoidable trace elements. A part formed from the cast iron alloy is also provided and the part has an Ac1 temperature equal to or greater than 895° C. and a thermo-mechanical fatigue lifetime of at least 10,000 cycles when cycled between 400° C. to 800° C. with a total cyclic strain equal to 0.001 m/m.

Godlewski, Larry Alan↗

Mesoscale modeling of microstructure-dependent thermal conductivity in U-Zr fuels

In uranium-zirconium (U-Zr) based metallic fuels, different phases can form at different compositions and temperatures. Typically, lamellar δ-UZr 2 and α-U phases are the dominant microstructures in U-rich U-Zr alloys at temperatures below 880 K. In this work, a finite element method based mesoscale modeling technique is used to calculate the effective thermal conductivities of such heterogeneous microstructures, using the thermal conductivities of two individual phases and their interphase thermal resistance (Kapitza resistance) as input parameters. The Kapitza resistance between δ-UZr 2 and α-U is determined at different temperatures, which shows an approximately T 3 dependence in the temperature range between 300 and 800 K. In addition, the Kapitza resistance exhibits a strong dependence on the aspect ratio of the δ-UZr 2 phase. Further, an analytical model is therefore developed to quantify the effects of both temperature and δ-UZr 2 aspect ratio on the Kapitza resistance. Using this newly developed Kapitza resistance model, the effective thermal conductivities of a number of δ-UZr 2 + α-U heterogeneous microstructures in U-Zr alloys, including non-lamellar microstructures, can be estimated accurately.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Grain boundary segregation in BCC vanadium-based alloys: Quantum-accurate computed segregation spectra and targeted experimental validations

Grain boundaries are critically important to the material performance of fusion reactor materials such as vanadium, particularly mechanical properties and irradiation resistance. A key challenge to the design and control of grain boundaries in vanadium alloys is the lack of quantitative data on grain boundary segregation. In this study, we combine computational and experimental methods to address this gap. Furthermore, using a machine learning-accelerated quantum mechanics/molecular mechanics approach, we calculated the segregation spectra for 28 transition metal elements in polycrystalline vanadium, and validated these predictions experimentally for a subset of solutes that sample a range of segregation behavior, specifically zirconium, titanium, and tungsten, using analytical transmission electron microscopy. Furthermore, the agreement between experiment and theory highlights the predictive capability of our approach. Critically, this work provides a comprehensive database of quantum-accurate solute segregation enthalpies in vanadium, enabling the development of advanced alloys for fusion reactors applications.

Fusion materials↗

Research Needs for Uranium-Zirconium- Based Metallic Fuels

The purpose of this report is to summarize the needs and present recommendations related to the future direction for U-Zr-based metallic fuel research (including binary U-Zr and ternary U-Pu-Zr alloys). These needs and recommendations were determined by subject matter experts from various institutions during a two-day workshop held at the University of Florida in November, 2019. During open-floor discussions, the highest priority gaps in our understanding of U-Zr-based fuels were down-selected, and near- and long-term needs that directly impact the implementation of these metallic fuels were identified. The identified near-term needs include investigation of the following phenomena: i) swelling and fission gas release, ii) fuel-cladding chemical interaction, iii) phase evolution/constituent redistribution, and iv) thermal properties of the fuels. The long-term needs are: i) investigation of fuel creep and plasticity and ii) fission product (lanthanide) transport. In addition, there was general agreement that all institutions and subject matter experts would benefit from an open-source metallic fuels database with thermophysical property and microstructural data, along with fuel operation/irradiation history, which should be regularly updated with vetted information from new experimental and computational investigations and used to advance metallic fuels research and development. Finally, we recommend that metallic fuel research should be ongoing and that fuel qualification and fuel optimization should be equally prioritized; research combining experiments with modeling and simulation has the largest potential impact.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Bench-Scale Electrolytic Dissolution of Quarter-Scale FCA Cans

In 2016, the Savannah River National Laboratory (SRNL) led, in support of and under sponsorship of the Department of Energy’s National Nuclear Security Administration (DOE/NNSA) Office of Material Management and Minimization (M3), the removal and transfer of the plutonium based Fast Critical Assembly (FCA) fuel from the Japan Atomic Energy Agency (JAEA) Tokai facility to the Savannah River Site (SRS). The team also included JAEA, multiple organizations in Savannah River Nuclear Solutions (SRNS), International Nuclear Services, and many other entities. The FCA fuel removal project completion was a key deliverable for M3 to the 2016 Nuclear Security Summit and constituted the largest inventory of weapons-usable plutonium removed under the nonproliferation program. The FCA materials consist of thousands of stainless steel (SS) clad plates and hundreds of SS clad rods. The FCA fuel elements were packaged in a carrier can and stored at SRS pending disposition of the fuel. Following an assessment of candidate disposition options, SRNS identified electrolytic dissolution (ED) as the most promising disposition option for the FCA plates and their preferred option was endorsed by DOE. This option entails electrochemically dissolving the entire FCA carrier can with fuel elements and was based on bench-scale laboratory testing and historical work on processing SS-clad and zirconium-clad uranium-based fuel in the H-Canyon electrolytic dissolver (last operated in 1980). The FCA plate consists of a plutonium-aluminum metal alloy core hermitically sealed in SS cladding.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

FAST irradiations and initial post irradiation examinations – Part I

The Advanced Fuels Campaign Fission Accelerated Steady-state Test (FAST) at Idaho National Laboratory (INL) completed its first irradiation cycle within the Advanced Test Reactor (ATR). The test focused on the irradiation of alloy fuel forms for use in sodium fast reactors. Tests included the use of fuel additives (Sn, Sb, and Pd) for reducing the gettering of lanthanide fission products, zirconium liners to mitigate fuel-cladding chemical interaction, and annular fuel geometry for sodium-free fuel designs. The first cycle of FAST testing was completed and a series of rodlets were removed for the initial post irradiation examination (PIE) of FAST rodlets. The rodlet irradiation conditions was evaluated using Monte Carlo N-Particle (MCNP) for as-run power history and COMSOL for temperature analysis. These rodlets include a set of low burnups (~2.5 % heavy metal [%FIMA]) control rodlets and a helium bonded annular rodlet (4.7 %FIMA). Initial non-destructive PIE has been completed and includes, visual inspection, neutron radiography and gamma scanning of the FAST rodlets. Radiography confirmed the integrity of the experiments as well as showing the complete filling of the annulus in the annular fuel at a modest burnup (4.7 %FIMA) and potential slumping of the cooler rodlets at lower burnup. Precision gamma scanning indicated mostly usual fission product behavior with the exception of the ceasium in the He-bonded annular fuel. Future destructive PIE will be necessary in order to fully understand the effects of accelerated irradiation on U-Zr metallic fuel behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Degradation and Failure Phenomena of Advanced Reactor Fuel Concepts: Sodium-Cooled Fast Reactor Metallic Fuel

The U.S. Nuclear Regulatory Commission (NRC) is anticipating licensing applications and commercial use of new fuel types in advanced nuclear power reactors that would be designed and built in the United States. Pacific Northwest National Laboratory (PNNL) is providing technical assistance to the NRC related to the newly proposed nuclear fuel and cladding designs that would be deployed in these reactors. This report focuses specifically on the metallic fuel that is being considered for sodium-cooled fast reactors and specifically on mechanisms that would cause damage or failure to the fuel under reactor operating conditions and design basis accident conditions. There is historic experience with both metallic and oxide fuels in experimental sodium-cooled fast reactors, but this report will focus solely on metallic fuel. Currently two U.S.-based reactor designers are engaged with the NRC in the application or pre-application review and considering a sodium-cooled fast reactor. TerraPower is engaged with NRC in pre-application review of its Natrium reactor. The current design for this fuel uses a sodium-bonded uranium-10wt% zirconium (U10Zr) fuel clad in HT9 stainless steel. ARC Clean Technology is engaged with NRC in pre-application review of its ARC-100 reactor. The current design for this fuel uses a sodium-bonded uranium-10wt% zirconium (U10Zr) fuel with steel cladding. This report will focus on this fuel system specifically, with broader information given regarding other metallic fuel systems with other stainless steel alloy claddings. To support the NRC’s readiness efforts, this report will identify and discuss degradation and failure modes of metallic fuel concepts for sodium-cooled fast reactors, including fuel performance characteristics that may not be addressed within existing regulatory documents.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Measurement of low energy characteristic X-rays emitted present in U-10Mo HALEU alloy fuel

Advance high density monolithic alloy HALEU fuels have been scanned with a silicon drift detector scanning system to measure low-energy characteristic X-rays emitted by uranium daughters, as well as zirconium present as a foil diffusion barrier. Four peaks were measured across the surfaces of three plates, and are consistent with other thorium and protactinium peaks present in depleted uranium samples that are induced by the decay of 235 U and 238 U. Of the four peaks detected, three are dominated by the decay of 235 U, and one peak at 15.70 keV covers two characteristic X-rays from the zirconium diffusion barrier (Kα 1 ) and from a 231 Th 15.62 keV X-ray induced by 235 U α-decay. The low energies of these lines suggest that they are mostly emitted from the fuel meat surface, and the poor counting statistics caused by strong self-attenuation make these data a poor candidate for 235 U/ 238 U ratio analysis. We suggest, then, that these X-rays could be used for passive measurement of variations in the cladding thickness of these fuels to complement manual thickness measurement methods.

HALEU↗